Inflatable structures

ABSTRACT

A method of forming a building structure in a desired contoured configuration. An inner supporting fabric is inflated into at least one form. An outer finishing fabric is draped over the inflated form. A coating is applied to the outer finishing fabric and a hardening shell is formed. The inner supporting fabric may be removed. Alternately, inflatable bags, posts, cables and other devices are disposed under the outer finishing fabric to produce the desired contoured configuration. These devices are removed after the coating has cured.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a continuation part of application Ser. No. 11/250,278, filed Oct. 14, 2005, which is incorporated herein

BACKGROUND OF INVENTION

The present invention relates to a method for forming structures and more specifically to a method of constructing a structure having a desired contoured configuration.

Inflatable forms for construction of structures have been known for many years. The inventor is aware of the following U.S. patents (two of which are his).

Inventor(s) Patent No. Bird et al. 3,225,413 Widmer 3,232,806 Fontaine 3,506,746 Turner 3,779,847 Bell, Jr. 3,801,685 Nicholson 4,041,671 Cappellini 4,170,093 Braine 4,365,455 Boyce 4,442,059 Thoeny 4,550,544 Dahl et al. 4,651,478 Thoeny 4,683,696 Hale 4,746,471 Vicino 4,799,982 Sallee 5,579,609

The problem with these references is the limitation of the shape of the structure formed n spacing using fabric. Present technology of forming fabric (non-woven, woven, knitted, etc.) permits the production of very large expanses of fabric which can be disposed over a skeletal structure to form a structure having a desired contoured configuration. Further, the prior art required considerable labor, time and materials. There is a need for a method of forming a structure having a desired contoured configuration at reduced costs and time, as well as obtaining unusual and artistic contours, undulations and configurations in the finished product.

OBJECT AND SUMMARY OF INVENTION

It is a primary object of the invention to provide a method of forming a structure having a desired contoured configuration, which is economical and easily constructed, as well as unusual and architecturally pleasing.

In accordance with the teachings of the present invention, there is disclosed a method of erecting a building structure including a roof and side walls having a desired contoured configuration to provide a visually appealing esthetic effect. A first inner supporting fabric is provided. The first inner supporting fabric is inflated forming at least one domed structure. A second outer finishing fabric is draped over the at least one domed structure. The second outer finishing fabric is supported substantially throughout by the inflated first inner supporting fabric and the second outer finishing fabric assumes the desired contoured configuration. The surface of the second outer finishing fabric is coated with a stiffener to thereby assure the rigidity of the desired contoured configuration in the building structure. The stiffener is allowed to cure. The first inner supporting fabric is deflated.

These and other objects of the present invention will become apparent from a reading of the following specification taken in conjunction with the enclosed drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of inflated forms.

FIG. 2 is an enlarged view of fabric draped over a portion of the inflated forms.

FIG. 3 is a perspective view of the outer fabric being disposed over the covered inflated forms.

FIG. 4 is a perspective view of the covered inflated form being sprayed.

FIG. 5 is a perspective view of the hardened shell.

FIG. 6 is a cross-sectional view taken across lines 6-6 of FIG. 5.

FIG. 7 is a perspective view of the shell having a stiffened edge member.

FIG. 8 is a top plan view of the structure having a stiffened edge member.

FIG. 9 is a diagram showing the method of forming the structure of the present invention.

FIG. 10 is a perspective view showing vertical supports disposed on a foundation.

FIG. 11 is a perspective view showing a first member draped over the supports.

FIG. 12 is a perspective view showing a second member draped over the first member.

FIG. 13 is a perspective view showing an exterior coating applied to the second member.

FIG. 14 is a cross-sectional view showing bags with varying amounts of inflation disposed beneath the outer finishing fabric.

FIG. 15 is a sequence of perspective views showing the inflation of a plurality of bags.

FIG. 16 is a cross-sectional view showing removable posts having adjustable lengths, disposed beneath the outer finishing fabric.

FIG. 17 is a cross-sectional view showing inflatable bags and supports disposed beneath the outer finishing fabric.

FIG. 18 is a cross-sectional view showing a liquid filled bladder disposed on the outer surface of the outer finishing fabric between elevated select portions.

FIG. 19 is a perspective view showing a cable drawn downwardly and forming a depression in an elevated portion of the outer surface of the outer finishing fabric.

FIG. 20 is an end view of FIG. 19.

FIG. 21 is a cross-section view of an elevated cable disposed against the inner surface of the outer finishing fabric.

FIG. 22 is a side elevation view of cables attached to the outer surface of the outer finishing fabric lifting the outer fabric in peaks.

FIG. 23 is a top plan view showing a typical contoured configuration of the present invention.

FIG. 24 is a side elevation view of FIG. 23.

FIG. 25 is a perspective view of a typical structure of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, an inflated form 10 or plurality of forms are prepared to provide a desired configuration of the structure. Although two inflated forms are shown in FIG. 1, the invention is not limited by the number or size of inflated forms nor is the positioning of the forms with respect to one another. The forms may be linearly aligned, in a circular arrangement, a polygonal configuration or randomly placed. The forms may be abutted or spaced apart from one another.

Although not necessary, the inflated form may have an internal skeletal structure such as supports or framing over which a first inner supporting fabric 12 is draped. A structure having an area greater than one acre or a structure the size of a house can be made. Compressed air, gas under pressure or pressurized air introduced by fans or heated air or water is introduced into the first inner supporting fabric 12 to inflate the fabric forming at least one domed structure. A second outer finishing fabric 14 is draped over the first inner supporting fabric 10 in its inflated condition (FIG. 2). The second outer finishing fabric 14 assumes the desired configuration based on the disposition of the inflated forms 10 (FIG. 3). The second outer finishing fabric 14 is supported substantially throughout by the inflated first inner supporting fabric 12 which may act as a release or separation between the first inner supporting fabric 12 and the second inner finishing fabric 14.

As shown in FIG. 4, the second outer finishing fabric 14 is sprayed or coated with a hardener or stiffener 16. The hardener or stiffener may be a plastic, cement or other desired material which assumes the shape and configuration of the surface of the outer finishing fabric. The hardener or stiffener sets up or cures to form a rigid hardened shell 18 (FIGS. 5-6). Additional coatings may be applied to the initial coating.

After the hardened shell 18 has been formed, and if desired, the inner form may be deflated and the inner supporting fabric may be removed, leaving the rigid structure in the desired configuration.

A stiffened edge member 20 (FIG. 6) may be attached to or formed on the peripheral edge of the outer finishing fabric 14 to better define the configuration of the shell 18. If desired, the edge member can be vertically or horizontally undulating, straight or of any desired shape (FIGS. 7-8). The stiffened edge member may be at ground level or may be elevated at various locations along the perimeter.

Alternately, (FIGS. 10-13), the structures may be formed using draped fabric over supports 22 of varying or equal heights which are not inflated. A foundation 24 is formed and vertical supports 22 are disposed peripherally around the foundation or within the structure itself that may meander in configuration. A first flexible unshaped member 26 which has a center portion and a peripheral portion 28 is draped over the vertical supports 22 such that the center portions disposed within the plurality of vertical supports. The peripheral portion 28 is disposed about the periphery of the foundation 24. The peripheral portion 28 may be attached to the foundation 24 if desired. The first unshaped member 26 has now acquired a generalized contoured configuration as determined by the supports in the foundation. A second sheet 30 of porous or substantially non-porous material is draped over the first member acquiring a desired contoured configuration. An exterior coating 32 is applied to the second sheet 30 of material. The exterior coating such as plastic or cement sets up and hardens to form a rigid surface having a desired configuration. The vertical supports are removed. A second inflated fabric may be introduced (FIGS. 11-12).

The draped fabric can also be sprayed from inside by relocating the inflatable forms.

There are other methods and structures to form structures with the desired contoured, undulating configuration. These methods and structures are directed to the means for obtaining the outer finishing fabric 14 in the desired configuration before the application of the hardener or stiffener. The outer finishing fabric may be a woven fabric, a welded wire fabric, expanded metal or other materials known to persons skilled in the art.

As shown in FIG. 14, inflatable bags 34 are disposed under the upper finishing fabric and are inflated to a different extent so that portions of the upper finishing fabric are varying elevations above the ground or surface level forming three dimensional curves and structures. After the upper finishing layer has been coated with the stiffener and has cured, the bags are deflated and removed. The bag 34 may be inflated with water or air.

FIG. 15 shows a means for inflating a plurality of bags wherein each bag 34 may be inflated to a desired degree and wherein each bag may be inflated to a degree different from the other bags. The figure shows a separate pump for each bag, however, it is possible to use a single pump and a controlling valve on the hose to each bag to limit the flow to the particular bag.

FIG. 16 shows at least one post 36 being deployed under the inner surface of the outer finishing fabric 14. Each post 36 may have an adjustable length to elevate the upper finishing fabric to a desired height so as to produce a contour or undulation. The post 36 may be elevated by a jack means. It is preferred that the top of each post which engages the inner surface of the outer finishing fabric be mushroom shaped or padded to reduce damage to the outer finishing fabric and to produce a rounded elevated portion (or crest) of the outer finishing fabric.

The combination of an inflatable bag 34 and posts 36 is shown in FIG. 17. The posts may be walls, columns or cones 38. An inverted cone placed under a trough in the outer finishing fabric supports the trough until the hardener or stiffener has cured or to remain in place. The cones/posts 14 may be removed after the stiffener has cured.

A bladder 40 having water or other fluid therein may be placed on the outer surface of the outer finishing fabric 14 as shown in FIG. 18. The bladder creates a depression in the outer finishing fabric between the elevated selected portions of the outer finishing fabric forming the desired contoured configuration. The outer finishing fabric may be spayed with the hardener or stiffener from the underside.

To form a different type of contoured surface, a cable 42 is disposed on the outer surface of the outer finishing fabric 14 and is drawn downwardly forming a depression (FIGS. 19, 20). A rope, line or other flexible means is considered to be a cable 42.

A cable 42 disposed against the inner surface of the outer finishing fabric 14 and elevated forms a raised portion to produce a desired contoured configuration (FIG. 21) subsequent to applying the stiffener.

As previously noted, a stiffened edge member 20 may be attached to the outer finishing fabric to create a variety of shapes as well as to control the edges of the fabric structure (FIG. 6).

As shown in FIG. 22, at least one cable is attached to the outer surface of the outer finishing fabric. The at least one cable is raised forming at least one peak or depression in the outer finishing fabric subsequent to applying the stiffener.

Any of the above-identified supports and forms or any combination thereof may be used to form the structure with the desired contoured or undulating configuration (FIGS. 23-25).

Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein. 

1. The method of erecting a building structure above the ground including a roof and side walls having a desired contoured configuration to provide an esthetic effect comprising the steps of: providing a first inner supporting fabric having an inner and outer surface; providing a plurality of spaced-apart supporting means to elevate selected portions of the outer finishing fabric higher above the ground than other portions of the outer fabric thereby forming a desired contoured configuration of the outer finishing fabric; coating the outer surface of the outer finishing fabric with a stiffener thereby assuring rigidity of the desired contoured configuration in the building structure; allowing the stiffener to cure; and removing the supporting means to elevate the selected portions thereby forming a single structure having the desired contoured configuration.
 2. The method of claim 1, wherein the means to elevate the selected portions of the outer finishing fabric is at least one inflatable bag disposed on the inner surface of the outer finishing fabric.
 3. The method of claim 2, wherein a plurality of inflatable bags are provided, each inflatable bag being inflated to a different extent.
 4. The method of claim 2, wherein the inflatable bag may be filled with water.
 5. The method of claim 1, wherein the means to elevate the selected portions of the outer finishing fabric is a plurality of posts disposed between the ground and inner surface of the outer finishing fabric.
 6. The method of claim 5, wherein each post has an adjustable length such that the elevation of selected portions of the outer finishing fabric may be at a desired height.
 7. The method of claim 1, wherein a bladder having water therein is placed on the outer surface of the outer finishing fabric thereby creating a depression in the outer finishing fabric between the elevated selected portions of the outer finishing fabric.
 8. The method of claim 1, further comprising a cable disposed on the outer surface of the outer finishing fabric, the cable being drawn downwardly thereby forming a depression in the outer finishing fabric and forming the desired contoured configuration.
 9. The method of claim 1, further comprising a cable disposed against the inner surface of the outer finishing fabric, the cable being elevated thereby elevating the outer finishing fabric and forming the desired configuration.
 10. The method of claim 1, further comprising at least one cable being attached to the outer surface of the outer finishing fabric, the at least one cable being raised, thereby forming at least one peak in the outer finishing fabric subsequent to applying the stiffener.
 11. The method of erecting a building structure including a roof and side walls having a desired configuration to provide an esthetic effect comprising the steps of: providing a first inner supporting fabric; inflating the first inner supporting fabric forming a first domed structure; providing at least a second inner supporting fabric, laterally spaced from the first inner supporting fabric, and inflating the at least second inner supporting fabric forming at least a second domed structure spaced apart from the first domed structure; varying the respective heights of the at least first and at least second laterally spaced-apart inner supporting fabrics; draping an outer finishing fabric over the at least one first domed structure and over the at least second domed structure wherein the outer finishing fabric is supported substantially throughout by the inflated first inner supporting fabric and the inflated second inner supporting fabric and the outer finishing fabric assumes the desired contoured configuration, forming a unitary covering all of the domed structures; coating a surface of the outer finishing fabric with a stiffener thereby assuring rigidity of the desired contoured configuration in the building structure; allowing the stiffener to cure; deflating the first inner supporting fabric and the at least second inner supporting fabric thereby forming a single layered structure having the desired contoured configuration.
 12. The method of claim 11, further comprising the steps of removing the first inner supporting fabric and the at least second inner supporting fabric from the building structure.
 13. An intermediary building structure, comprising an inflated first inner supporting fabric, and a laterally spaced-apart inflated second inner supporting fabric, means for varying the respective heights of at least one of the first and second laterally spaced-apart inner supporting fabrics, an outer finishing fabric draped over the inflated first inner supporting fabric and over the inflated second inner supporting fabric and arranged to obtain a unitary covering over the inflated first inner supporting fabric and over the spaced-apart inflated second inner supporting fabric in a desired configuration to achieve an architecturally pleasing esthetic effect and further including a hardening coating on the outer finishing fabric.
 14. An intermediary building structure erected above the ground, comprising an outer finishing fabric having an inner surface and an outer surface, the outer finishing fabric having selected laterally spaced-apart portions higher above the ground than other portions of the outer finishing fabric, the structure having removable means disposed under the outer finishing fabric to elevate selected portions of the outer finishing fabric to form a desired contoured configuration.
 15. The structure of claim 14, wherein the removable means are at least one inflatable bag disposed against the inner surface of the outer finishing fabric.
 16. The structure of claim 14, wherein the removable means are a plurality of posts having adjustable lengths, the posts being disposed between the ground and the inner surface of the outer finishing fabric.
 17. The structure of claim 14, wherein the removable means is a cable disposed on the outer surface of the outer finishing fabric, the cable being drawn downwardly thereby forming a depression in the outer finishing fabric.
 18. The structure of claim 14, wherein the removable means is a cable disposed against the inner surface of the outer finishing fabric, the cable being elevated thereby forming the desired contoured configuration.
 19. The structure of claim 14, wherein the removable means is at least one cable attached to the outer surface of the outer finishing fabric, the at least one cable being raised to form at least one peak or depression in the outer finishing fabric.
 20. The intermediary building structure of claim 14, further including a hardening coating on the outer finishing fabric. 